Series AV2000/3000/4000/5000Soft Start-up Valve

Low power consumption

With supply/exhaust function by manual operation

Combination with F.R.L. unit

Connectable with modular typeF.R.L. combination unit

AC20 AC25 AC30 AC40

AV2000

AV3000

AV4000

AC50 AC60

AV5000

F.R.L. combinationSoftstart-up valve

(Except AC40-06)

AV5000

F.R.L. combination

Soft start-up valve

Start-up valve for low speed air supply to gradually raise initial pressure in an air system and for quick exhaust by cutting off air supply.

Large effective area (mm2)AV2000/ 20 (Body size: 1/4)AV3000/ 37 (Body size: 3/8)AV4000/ 61 (Body size: 1/2)AV5000/ 113 (Body size: 3/4)AV5000/ 122 (Body size: 1)

[Option]

593

AC-A

AF-A

AF-A

AR-A

AL-A

AW-A

AC

AF

AF

AR

AL

AW

AG

E

AV

AF

AV

Flow directionNilR

Left to rightRight to left

AV 00 1 G

Body size20304050

1/43/81/2

3/4,1

Electrical entry

Coil rated voltat1234567

100 VAC (50/60 Hz)200 VAC (50/60 Hz)

110 to 120 VAC (50/60 Hz)220 VAC (50/60 Hz) 24 VDC 12 VDC 240VAC (50/60 Hz)

Thread typeNilFN

RcG

NPT

Manual overrideNil: Non-locking push type (Flush)

B: Locking type (Tool required)

20 02

Soft start-up valve

Port size0203040610

1/4 (AV2000 only)3/8 (AV3000 only)1/2 (AV4000 only)3/4 (AV5000 only)1 (AV5000 only)

OptionNilG

NoneWith pressure gauge

C: Locking type (Lever)

Light/Surge voltage suppressorNilSZ

CE-compliant

NoneWith surge voltage suppressor (Grommet type only)With light/surge voltage suppressor (Not possible with grommet type)

How to Order Pilot Valve Assembly

G: Grommet Note 1)

D: Type D DIN terminal (With connector)

Y: Type Y DIN terminal (With connector)

How to Order

[Option]Note) CE compliant: “G”, grommet

is not available.

Flow directionNilR

Left to rightRight to left

DO: Type DDIN terminal (Without connector)

YO: Type YDIN terminal (Without connector)

Note 1) The grommet type can have a surge voltage suppressor (direct coupling type lead wire), but without indicator light.

SF4 1 G 80Rated coil voltage

1234567

100 VAC (50/60 Hz)200 VAC (50/60 Hz)

110 to 120 VAC (50/60 Hz)220 VAC (50/60 Hz) 24 VDC 12 VDC 240 VAC (50/60 Hz)

Electrical entryGDY

DOYO

Grommet Note 1)

Type D DIN terminal (With connector)Type Y DIN terminal (With connector)Type D DIN terminal (Without connector)Type Y DIN terminal (Without connector)

Note 1) The grommet type can have a surge voltage suppressor (direct coupling type lead wire), but without indicator light.

Light/Surge voltage suppressorNilSZ

NoneWith surge voltage suppressor (Grommet type only)

With light/surge voltage suppressor(Not possible with grommet type)

Manual overrideNilBC

Non-locking push type (Flush type)Locking type (Tool required)Locking type (Lever type)

Soft start-up valve

CE-compliantNilQ

—CE-Compliant Note 2)

Note 2) “G”, grommet is not available.

—

—CE-compliant

Soft Start-up Valve

AV2000/3000/4000/5000

CE-compliantNilQ

—CE-Compliant Note 2)

Note 2) “G”, grommet is not available.

For other rated voltages, please consult with SMC.

For other rated voltages, please consult with SMC.

594

2(A)

3(R)

1(P)2

110

212

10

31

1

12

10

12

32

Model

Port size

Proof pressure

Operating pressure range

Pressure gauge port size

Ambient and fluid temperature

Effective area (mm2)

Weight (kg)

Rated coil voltage

Allowable voltage fluctuation

Coil insulation type

Apparent power (Current consumption)

Current consumption DC

Electrical entry

Option specifications

Pilot valve manual override

AV2000

1/4

20

24

0.27

AV3000

3/8

37

49

0.48

100, 200, 110 to 120, 220 VAC (50/60 Hz), 240 VAC (50/60 Hz) 12, 24 VDC

–15 to +10% of rated voltage

Equivalent to B type (130°C)

5.6 VA (50 Hz), 5.0 VA (60 Hz)

3.4 VA (2.1 W)/50 Hz, 2.3 VA (1.5 W)/60 Hz

1.8 W

Grommet, Type D DIN terminal, Type Y DIN terminal

Indicator light/Surge voltage suppressor (2)

Non-locking push type (Flush), Locking type (Tool required), Locking type (Lever)

AV4000

1/2

61

76

0.74

113

132

1.60

122

141

1.54O

utle

t pre

ssur

e (M

Pa)

Needle Valve Flow Characteristics

Air

flow

rat

e (L

/min

(A

NR

))

Inlet pressure 0.5 MPa

Needle rotations

DescriptionPart no.

Pressure range

Pressure gaugeG36-10-01

1 MPa

Specifications

AV5000

3/4 1

Inrush

Energized

Piston B Switching Pressure (Close Open)

0.5

0

200

400

600

800

1000

1200

1400

1600

1800

2000

0.1

0.2

0.3

0.4

0.60.1 0.2 0.3 0.4 0.5 0.7 0.8 0.9 1.0

Inlet pressure (MPa)

0 1 2 3 4 5

Accessory/Pressure Gauge

Symbol

AC

0

1.5 MPa

0.2 to 1 MPa

1/8

0 to 60°C (1)

AV4000

AV5000

AV3000

AV2000

Type Y DIN terminal

Type D DIN terminal

Ele

ctri

cal s

pec

ific

atio

ns

1(P) 2(A)

2(A) 3(R)

Note 1) Use dry air when operating at a low temperature.Note 2) The grommet type is equipped with a surge voltage suppressor (direct coupling type lead wire),

but not an indicator light.

Soft Start-up Valve Series AV2000/3000/4000/5000

595

AC-A

AF-A

AF-A

AR-A

AL-A

AW-A

AC

AF

AF

AR

AL

AW

AG

E

AV

AF

AV

When 1/2 PP ≤ PA after the cylinder reaches B , piston B t fully opens and PA increases rapidly as shown from C to D and becomes the same pressure as PP.

Pilotvalve

ON

Cylinder drive circuit (Meter-out control) example

ON OFF

1(P) 2(A)

3(R) B

B

Working description

OFF —

B-B

Working Principle

Initial Operation Return Stroke

Time

Pre

ssur

e st

roke

Cylinder m

ovement w

ith fixed orific

e

PR (Atmospheric pressure)

PA

PP

B

D

C

A

5

2

3

4

1

6

7

Workingcondition

Low speed supply

Quick exhaust

Normal operation

High speedsupply

Pressureconditions

1/2 PP > PA

1/2 PP ≤ PA

1/2 PP ≅ PA

Pressure time chart (Meter-out control) example

Series AV2000/3000/4000/5000

When pilot valve w is turned ON by energization or manual override, the pilot air pushes piston A e and main valve q downward and opens main valve q while R port closes simulta-neously. The air from P portmoves to needle valve u , where its flow is adjusted, and flows to A port. The meter-in control of needle valve u slowly moves the cylinder from A to B.

Since piston B t holds the fully open condition, during normal operation the cylinder’s speed will be controlled by the usual meter-out control.

When pilot valve w is turned OFF, spring r pushes piston A e and main valve q upward and opens R port while shutting off the air supply from P port.The pressure difference generated at this time lets the check valve y open and the residual pressure on the A port side is quickly exhausted from R port.

1(P)PP

3(R)

2(A)

PA

2

10

31

1

10

12

3

23

12

41

14

52

110

21

12

2

1(P)PP

3(R)

2(A)

PA

23

12

41

14

5

2

110

212

10

31

1

12

10

12

32

1(P)PP

3(R)

2(A)

PA

23

12

41

14

5

2

110

212

10

31

1

12

10

12

32

596

No.

123

BodyCapCover

Material

Aluminum die-casted

Aluminum die-casted

Aluminum die-casted

Replacement Parts

Pilot valve assemblyPiston A assemblyPiston B assemblyMain valve assemblyCheck valvePiston guide assemblyNeedle assemblyValve springPiston springCheck springNeedle springType C retaining ring for shaftType C retaining ring for holeSealSealO-ring

POM, NBR

Brass, NBR (HNBR)

Brass, NBR (HNBR)

Brass, NBR (HNBR)

POM, NBR

Brass, NBR

Steel wire

Stainless steel

Stainless steel

Steel wire

Tool steel

Tool steel

NBR

NBR

NBR

AV2000

P424204A

P424205A

P424206A

P424207

P424208A

P424209A

P424211

P424212

P424213

P424214

G-5

0-9

P424210

P424218

10 x 8 x 1

AV3000

P424304A

P424305A

P424306A

P424307

P424308A

P424309A

P424311

P424312

P424313

P424314

STW-5

0-10

P424310

P424315

11 x 9 x 1

AV4000

P424404A

P424405A

P424406A

P424407

P424408A

P424409A

P424411

P424412

P424413

P424414

STW-8

RTW-12

P424410

P424415

12.5 x 9.5 x 1.5

∗1 For “How to Order” pilot valve assembly, refer to page 594.

Component PartsDescription

ON OFF

1(P) 2(A)

B

B3(R)

456789

10111213141516171819

MaterialAV5000

P424504A

P424505A

P424506A

P424507

P424508A

P424509A

P424511

P424512

P424513

—

STW-10

RTW-15

P424510

P424514

16.5 x 12.5 x 2

DescriptionNo.Part no.

B-B

Construction

4

5

15

18

11

7

17

19

10

14

16

12

13

3

9

6

1

8

2

SF4--80∗1(-Q)

Soft Start-up Valve Series AV2000/3000/4000/5000

597

AC-A

AF-A

AF-A

AR-A

AL-A

AW-A

AC

AF

AF

AR

AL

AW

AG

E

AV

AF

AV

DIN terminal: AV00--D, DZDIN terminal for European use: AV00--Y, YZ

With light/surge voltage suppressor

AV2000-02-GAV2000-02-GSAV2000-02-DAV2000-02-DZAV2000-02-YAV2000-02-YZAV3000-03-GAV3000-03-GSAV3000-03-DAV3000-03-DZAV3000-03-YAV3000-03-YZAV4000-04-GAV4000-04-GSAV4000-04-DAV4000-04-DZAV4000-04-YAV4000-04-YZAV5000- -GAV5000- -GSAV5000- -DAV5000- -DZAV5000- -YAV5000- -YZ

1/4

1/4

1/4

3/8

3/8

3/8

1/2

1/2

1/2

3/4, 1

3/4, 1

3/4, 1

66

66

66

76

76

76

98

98

98

128

128

128

105

125

125

112

132

132

127

147

147

155

175

175

31

31

31

36

36

36

47

47

47

59

59

59

22

22

22

24

24

24

32

32

32

39

39

39

40

40

40

48

48

48

52

52

52

74

74

74

38

38

38

43

43

43

57

57

57

77

77

77

0

0

0

2

2

2

3

3

3

0

0

0

47.5

—

—

50.5

—

—

62.5

—

—

74

—

—

Grommet: AV00--G, GS

SMC

MAD

E IN

JAP

AN

SMCM

ADE

IN JA

PAN

ON OFF OFFON

300 mm (Lead wire length)

Manual override(Locking lever type)

Port size

36.8 E

ø37

N

CQ

H

Pressure gaugemounting

bore 1/8

P

R

P

B

G

IA

4 x R

D

LKA M

G

Applicable cab tire cord O.D.: ø6, ø8

Manual override (Locking lever type)

P A

R

D

B

CQ

H

Indicator light

P

4 x R 36.8 E

ø37

Model Portsize

A B C D E G H I

A

Pressure gauge mounting bore 1/8

—

65.5

—

67.5

—

—

66.5

—

70.5

—

—

78.5

—

82.5

—

—

90

—

94

—

—

—

80.5

— 84.5

—

— 83.5

—

87.5

—

—

95.5

—

99.5

—

—

107

—

111

—

6

23

10.5

27.5

—

—

16

3.5

20.5

—

—

6

—

10.5

—

—

—

—

—

93

—

—

100

—

—

115

—

—

143

—

—

29

29

29

28

28

28

42

42

42

50

50

50

23.5

23.5

23.5

27.5

27.5

27.5

37

37

37

46

46

46

M4 x 0.7Depth 4.5

K L M N P Q R

M6 x 1Depth 6

M6 x 1Depth 7.5

M6 x 1Depth 7.5

M6 x 1Depth 7.5

M6 x 1Depth 6

M6 x 1Depth 6

M5 x 0.8Depth 5

M5 x 0.8Depth 5

M5 x 0.8Depth 5

M4 x 0.7Depth 4.5

M4 x 0.7Depth 4.5

+-+-

0610

0610

0610

0610

0610

0610

Dimensions

Series AV2000/3000/4000/5000

598

Y200Y300Y400Y600

AV2000

AV3000

AV4000

AV5000

Applicable modelModel

Spacer Spacer with bracket

Y200T Y400T

Y200TY300TY400TY600T

AV2000

AV3000

AV4000

AV5000

Applicable modelModel

Y200 Y400

Connecting Spacer for Modular Style F.R.L. Unit

Select one of the spacers below when connecting to an F.R.L. combination unit (AC20 to AC60).(Spacers must be ordered separately.)

Soft Start-up Valve Series AV2000/3000/4000/5000

599

AC-A

AF-A

AF-A

AR-A

AL-A

AW-A

AC

AF

AF

AR

AL

AW

AG

E

AV

AF

AV

SelectionCaution on Design

Warning Caution

AC coil is 20% or less of rated voltage.DC coil is 3% or less of rated voltage.

Selection

Warning

Mounting

Warning

Adjustment

Caution

1. Actuator driveWhen using solenoid valve or actuator in the outlet side of this product, implement appropriate measures to prevent potential danger caused by actuator operation.

2. Holding pressureSince the valve might have slight interal leakage, it is not suitable for holding pressure in a tank or another vessel for a long period of time.

3. Maintenance spaceAllow the sufficient space for maintenance and inspection.

1. Confirm the specifications.The products presented in this catalog are designed only for use in compressed air systems. Do not operate at pressures or temperatures, etc., beyond the range of specifications, as this can cause damage or malfunction. (Refer to specifica-tions.) Please contact SMC if using for other fluids than compressed air.

2. Extended periods of continuous energizationPlease contact SMC if valves will be continuously energized for extended periods of time.

3. Operation of closed center solenoid valvesEven if this product is used for closed center solenoid valves or actuator with a load factor of more then 50%, jumping (stick-slip phenomenon) cannot be prevented.

4. Using a regulator in the outlet sideWhen mounting a regulator in the outlet side (A port side), use a residual pressure relief regulator (AR25K to 40K) or a check type regulator. With a standard regulator (AR10 to 60), the outlet side pressure may not be released when this valve is exhausted.

5. Operation of solenoid valves in the outlet sideTo operate solenoid valves mounted on this product’s outlet side (A port side), first confirm that the outlet side’s pressure (PA) has increased to become equal to the inlet side’s pressure (PP).

6. OperationThe residual pressure release function of this product is for emergency use only; therefore, avoid the operation in the same manner as ordinary 3 port valves.

7. Using a lubricatorIf mounting a lubricator, mount it on the inlet side (P port side), of this product. If mounted on the outlet side (A port side), back flow of oil will occur and may spurt out of the valve’s R port.

8. Operation for air blowingThis product cannot be operated for air blowing due to the mechanism that switches the main valve to be fully open after the outlet side’s pressure increases to approximately 1/2 of the inlet side.

1. Voltage leakageParticularly when using a C-R element (surge voltage suppressor) for protection of the switching element, use cation that leakage voltage will increase due to leakage current flowing through the C-R element, etc.

2. Low temperature operationAlthough the valve can be operated at temperature as low as 0°C, measures should be taken to avoid solidifying or freezing drainage and moisture, etc.

1. If air leakage increases or equipment does not operate properly, stop operation.After mounting or maintenance, etc., connect the compressed air and power supplies, and perform appropriate function and leakage tests to confirm that the unit is mounted properly.

2. Instruction manualMount and operate the product after reading the manual carefully and understanding its contents. Also keep the manual in a place where it can be referred to as necessary.

3. Painting and coatingWarnings or specifications printed or labeled on a product should not be erased, removed or covered up.Furthermore, please contact SMC before painting the resin parts, as this may cause adverse effects depending on the solvent.

1. To perform the initial speed adjustment of a outlet side actuator, supply air from this valve’s inlet side and turn ON the pilot valve. Then, rotate the needle counterclockwise from the fully closed position.

Series AV2000/3000/4000/5000Specific Product Precautions 1Be sure to read before handling. Refer to front matter 43 for Safety Instructionsand pages 365 to 369 for F.R.L. Precautions.

C R

Switching element

OFF

Leakage currentValve

Powersupply

Leak

age

volta

ge

600

Light/Surge Voltage Suppressor

CautionPiping

Caution

Connection threads

Rc 1/4

Rc 3/8

Rc 1/2

Rc 3/4

Rc 1

12 to 14

22 to 24

28 to 30

28 to 30

36 to 38

Proper tightening torque (N·m)

Tightening Torque when Piping

Windingdirection

Pipe tapeExpose approx. 2 threads

Lubrication

Caution

Model

AV2000

AV3000

AV4000

AV5000

5

22

35

50

Composite effective area (mm2)

Voltage AC and 100 VDC 24 VDC or less

Electrical

circuit

Terminal

DIN terminal

1

+

2

–

DIN terminal

1 2

Electrical Connection

Caution

1. Preparation before pipingBefore piping is connected, it should be thoroughly blown out by air (flushed) or washed to eliminate cutting chips, cutting oil, and other debris from the pipe inside.

2. How to wrap a pipe tapeWhen connecting pipes and fittings, etc., ensure that cutting chips and sealing materials from the pipe threads should not get inside the valve. When a pipe tape is used, leave 1.5 to 2 thread ridges exposed at the end of the pipe.

3. Tighten threads with the proper tightening torque.When screwing fittings into valves, tighten with the torques given below.

4. Piping to productsWhen piping to products, avoid making an error of supply port, etc., by referring to the instruction manuals.

5. F.R.L. module combinationWhen connecting to a modular F.R.L. combinations (AC20 to 60), select one of the spacers, which are included. (Refer to page 599 for details.) However, modular combinations with AC40-06 are not possible.Furthermore, connect soft start-up valves to the outlet side of the F.R.L. combination.

6. Inlet side piping conditionsThe nominal size of the piping material’s or equipment’s bore should be equal to or larger than the soft start-up valve’s port size. The composite effective area of the inlet side’s (P port side’s) piping or equipment should be equal to or larger than the values below.

When the piping is restricted or the supply pressure is insufficient, the main valve will not switch and air leakage may occur from the R port.

The internal connection of the DIN terminal is as shown below,connect to the power supply side as shown.

1. The valve has been lubricated for life at the factory, and does not require any further lubrication.

2. Use turbine oil Class 1, ISO VG32 (with no additives), if lubricated. Besides, if the lubrication is suspended halfway, the original lubricant will be lost and may result in a malfunction. Be sure to keep lubricating continuously.

Note) Refer to SMC’s website for details about each manufacturer’s brand name of class 1 turbine oil (no additive) ISO VG32. Ad-ditionally, please contact SMC for details about class 2 turbine oil (with additives) ISO VG32.

Series AV2000/3000/4000/5000Specific Product Precautions 2Be sure to read before handling. Refer to front matter 43 for Safety Instructionsand pages 365 to 369 for F.R.L. Precautions.

Var

isto

r

−(+)

+(−)

Note) There is no polarity (+ or –)

SOL.

With indicator light

Terminal no. 2 – (+)

Terminal no. 1 + (–)

SOL.

With indicator light

Terminal no. 2 (–)

Var

isto

r

Terminal no. 1 (+)

601

AC-A

AF-A

AF-A

AR-A

AL-A

AW-A

AC

AF

AF

AR

AL

AW

AG

E

AV

AF

AV

Air Supply

Warning

Caution

Maintenance

Warning

CautionOperating Environment

Warning

1. Use clean air.Do not use compressed a i r which conta ins chemicals , synthetic oils containing organic solvents, salts or corrosive gases, etc., as this can cause damage or malfunction.

1. Install air filters.Install air fi lters close to valves at their upstream side. A filtration degree of 5 µm or less should be selected.

2. Implement countermeasures by installing after-cooler or air dryer, or water separator, etc.The air including excess drain may result in a malfunction of v a l v e s a n d o t h e r p n e u m a t i c e q u i p m e n t . I m p l e m e n t countermeasures by installing after-cooler or air dryer, or water separator, etc.

1. Do not use valves in such environments where corrosive gases, chemicals, or brine or water or steam is airborne, or where valves can be directly exposed to any of those.

2. Do not use in an explosive environment.3. Do not use in locations influenced by vibrations or

impacts. 4. A protective cover, etc., should be used to shield

valves from direct sunlight. 5. Shield valves from radiated heat generated by

nearby heat sources.6. Take suitable protective measures in locations

where there are contacts with water droplets, oil, or welding spatter, etc.

7. In a dusty environment or when valve switching noise is intrusive, install a silencer in the R port to prevent dust from entering, and to reduce noise.

1. Perform maintenance and inspection as shown in the instruction manual. If handled improperly, damage may occur in machine or equipment or an operational error may result in.

2. Equipment removal and supply/exhaust of com-pressed airWhen equipment is removed, first confirm that measures are implemented to prevent dropping of workpiece and runaway of equipment, etc. Then cut the supply pressure and power, and exhaust all compressed air from the system using its residual pressure release function.

3. Low frequency operationValves should be switched at least once every 30 days to prevent malfunction. (Use caution regarding the air supply.)

4. Manual override operationWhen the manual override is operated, connected equipment will be actuated.Confirm the safety before operating.

1. Drain removalRemove drain from air filters periodically.

How to Find the Flow Rate (At air temperature of 20°C)

293273 + t

Choke flow: (P2 + 0.1)/(P1 + 0.1) � 0.5

Subsonic flow: when (P2 + 0.1)/(P1 + 0.1) > 0.5

Q = 120 x S x (P1 + 0.1) x

Q: Air flow rate [L/min (ANR)]S: Effective area (mm2)P1: Inlet pressure [MPa]P2: Outlet pressure [MPa]t: Air temperature [°C]

Note 1) Formulas above are applied to pneumatics only.

Q = 240 x S x (P1 – P2)(P2 + 0.1) x 293

273 + t

Series AV2000/3000/4000/5000Specific Product Precautions 3Be sure to read before handling. Refer to front matter 43 for Safety Instructionsand pages 365 to 369 for F.R.L. Precautions.

602